Tool for positioning templates with respect to curved rail

ABSTRACT

A tool for positioning a plurality of templates with respect to a curved rail includes a flexible spine that carries a plurality of templates. Each of the templates defines an opening adapted to guide a cutting tool to form a picket hole in the rail. The templates are evenly spaced along the longitudinal direction of the flexible spine so that the picket holes are evenly spaced when cut. A clamp may be associated with each template to hold the tool with respect to the rail.

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority from U.S. Patent Applicationserial No. 60/461,567 filed Apr. 9, 2003; the disclosure of which isincorporated herein by reference.

BACKGROUND OF THE INVENTION

[0002] 1. Technical Field

[0003] The present invention generally relates to methods and tools usedto form the picket holes in curved fence rails. More particularly, thepresent invention relates to a flexible tool that automatically adjuststo the curvature of the rail to automatically position a plurality oftemplates at the locations for the picket holes.

[0004] 2. Background Information

[0005] Low maintenance vinyl fences and vinyl decking are becomingincreasingly popular as their appearance approaches traditional woodstructures. These structures generally have top and bottom rails thatextends between vertical posts. A plurality of spaced parallel picketsare connected to the top and bottom rails and are evenly spaced betweenthe posts. Picket holes must be cut in the upper surface of the bottomrail and in the lower surface of the top rail to receive the pickets. Inorder to maintain parallel and evenly spaced pickets, the picket holesmust be carefully planned and cut. When the top and bottom rails arestraight, the planning and cutting is not too difficult. A router may beused with a simply template to cut the openings along the longitudinalcenterline of the rails.

[0006] Structures with curved rails are also becoming increasinglydesired given their aesthetic features and their ability to simulatetraditional wooden structures. Those skilled in the art of vinylstructures have found the task of cutting picket holes in curved vinylrails difficult. The radii of curved vinyl rails varies because of thematerial properties and methods of forming the curved rails. Thedifferent radii prevent a fixed template from being used to locate thepicket holes. As such, the location of each picket hole must be measuredmanually. Once the hole location is marked, a template is position and acutting tool, such as a router, is used to form the hole. Although thisprocess is effective, the art desires a method and a tool for quicklyand easily laying out and cutting all the picket holes in a curved rail.

BRIEF SUMMARY OF THE INVENTION

[0007] The invention provides a tool that is used to locate the picketholes on a curved fence rail. The tool automatically adjusts to thecurvature of the rail while automatically positioning a plurality oftemplates at the proper locations for the picket holes. The toolgenerally includes a flexible spine with a plurality of templatesmounted to the spine. In one embodiment of the invention, the toolincludes a clamp aligned with each template to securely hold the curvedrail with respect to the templates.

[0008] The invention also provides a method for forming the picket holesin a curved rail wherein the curved rail is slid into a flexible toolthat automatically adjusts its curvature to the curvature of the rail.The method includes the step of fixing the position of the tool withrespect to the rail and forming the picket holes in the rail.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0009]FIG. 1 is a perspective view of a curved fence section having apair of curved fence rails disposed between a pair of fence posts.

[0010]FIG. 2 is a top plan view of the first embodiment of the tool ofthe present invention.

[0011]FIG. 3 is a bottom plan view of the first embodiment of the toolof the present invention.

[0012]FIG. 4 is an enlarged view of the encircled portion of FIG. 3.

[0013]FIG. 5 is a top plan view of the first embodiment of the tool anda curved rail.

[0014]FIG. 6 is a top plan view of the first embodiment of the tool witha curved rail clamped into the tool and ready for cutting.

[0015]FIG. 7 is a section view taken along line 7-7 of FIG. 6.

[0016]FIG. 8 is a section view taken along line 8-8 of FIG. 6 showing acutting tool ready to cut a picket hole.

[0017]FIG. 9 is a view similar to FIG. 8 showing the cutting toolforming the picket hole.

[0018]FIG. 10 is a top plan view of the second embodiment of the tool ofthe present invention.

[0019]FIG. 11 is a section view taken along line 11-11 of FIG. 10.

[0020]FIG. 12 is a top plan view of the second embodiment of the tooland a curved rail.

[0021]FIG. 13 is a top plan view of the first embodiment of the toolwith a curved rail clamped into the tool and ready for cutting.

[0022]FIG. 14 is a section view taken along line 14-14 of FIG. 13.

[0023] Similar numbers refer to similar parts throughout thespecification.

DETAILED DESCRIPTION OF THE INVENTION

[0024] The two preferred embodiments of the tool of the invention areindicated generally by the numerals 100 and 102 in the accompanyingdrawings. Each tool 100 and 102 is adapted to automatically adjustitself to the curvature of a rail 104 that is placed within tool 100 or102. Each tool 100 and 102 is also adapted to automatically position aplurality of templates 106 with respect to rail 104 so that the picketholes may be cut into curved rail 104 without excessive, time consumingmeasuring.

[0025] Each template 106 may be a locating template that is used to markthe picket hole location or a cutting template that defines an openingsized and shaped to receive an appropriate cutting element—such as arouter bit—that is designed to cooperate with the opening to cut apicket holes in a surface of rail 104. In the preferred embodiment ofthe invention, each opening on each template 106 is sized to cooperatewith the collar on a router bit to properly position the router bit(FIG. 9) to cut a perfect opening that receives the end of a picket in afence 10 (FIG. 1). Each template 106 is designed for the picket that isintended to be used with rail 104. Different templates 106 are used fordifferent pickets. As such, different tools 100 or 102 may be designedfor use with different pickets. Further, different tools 100 or 102 maybe designed for use with different picket spacing. Tool 100 and 102 is,however, designed to work with endless degrees of curvature between theupper and lower limits of the tool. In another embodiment of theinvention, the positions of the templates with respect to the tool areadjustable so that the tool may be set up for different picket spacing.

[0026] Each tool 100 and 102 includes a flexible spine 1 10 that carriestemplates 106 such that the opening in template 106 is properlypositioned with respect to rail 104. The opening in each template may becentered with respect to the cross sectional width of rail 104 as shownin FIGS. 7 and 14.

[0027] In tool 100, spine 110 defines a plurality of spaced slots 111that increase the flexibility of spine 110. In cross section, the spineon tool 100 has a height equal to its width and may be 1-½ inch by 1-½inch in cross section. In this embodiment, the spine acts as its ownclamp support as shown in FIG. 7 such that rail 104 is clamped againstspine 110 with a plurality of clamps that are removed from tool 100 whenall of the holes are cut in rail 104. In tool 102, spine 110 has a thinwidth compared to its height in cross section. The thin width allowsspine 110 to bend without the need for slots 111. In both embodiments,spine 110 may be fabricated for a flexible material such as plasticlumber.

[0028] In the second embodiment, a clamp support 112 is attached tospine 110 at each template 106. A clamp 114 is attached to each clampsupport 112 as shown in FIG. 11 with a portion of spine 110 beingdisposed between clamp 114 and clamp support 112. Clamps 114 may besecurely mounted (i.e.: with threaded fasteners) to supports 112 suchthat clamps 114 remain in place after the holes are formed in rail 104.The clamping force of clamp 114 is adjustable to accommodate variationsin rail 104 thickness.

[0029] In tool 102, a flexible cover 116 is disposed between each clamp114 and spine 110 to protect rail 104 and spread the clamping force ofclamps 114 to a wider area of rails 104. Flexible cover 116 may also befabricated from flexible lumber. Cover 116 has a length at least as longas the span of clamps 114 and may have a length equal to or greater thanspine 110.

[0030] Each template 106 may have angled sidewalls or angled cornersthat allow templates 106 to pivot toward each other when a sharplycurved rail 104 is inserted into tool 100 or 102 as shown in FIGS. 6 and13. The angles prevent the templates 106 from interfering with eachother.

[0031] In the two embodiments of the invention shown in the drawings,the distance between each template 106 is fixed and the spacing betweenthe template 106 hole and the spine 110 is fixed. In other embodimentsof the invention, these distances may be adjustable by providing thetemplates with adjustable connections.

[0032] In use, the person needing a curved fence section 10 first formsa pair of rails 104 into the desired curve by know bending techniques.The user then inserts curved rail 104 into tool 100 or 102. In tool 100,the person bends tool 100 around curved rail 104 and clamps tool 100 inplace as shown in FIGS. 6 and 7. In tool 102, the user slides rail 104into tool 102 and allows tool 102 to automatically accommodate thecurvature of rail 104. The user then positions one end of tool 100 or102 with respect to rail 104 to automatically position templates 106with respect to rail 104. Tools 100 and 102 also allow the personcutting the holes to view the entire layout before cutting. Thisoverview gives the user the chance to eliminate layout mistakes thatwould otherwise result in a scrapped piece of material. Each tool 100and 102 may be used on a straight rail 104 having an infinite radius ofcurvature to a rail 104 having a radius of curvature that is smallenough to cause templates 106 to interfere with each other.

[0033] In the foregoing description, certain terms have been used forbrevity, clearness, and understanding. No unnecessary limitations are tobe implied therefrom beyond the requirement of the prior art becausesuch terms are used for descriptive purposes and are intended to bebroadly construed.

[0034] Moreover, the description and illustration of the invention is anexample and the invention is not limited to the exact details shown ordescribed.

1. A tool for positioning a plurality of templates with respect to acurved rail having a curvature; the tool comprising: a flexible spinehaving a longitudinal direction; the flexible spine adapted to conformto the curvature of the curved rail; a plurality of templates connectedto the flexible spine; each of the templates defining an opening adaptedto guide a cutting tool to form a picket hole in the rail; and thetemplates being evenly spaced along the longitudinal direction of theflexible spine.
 2. The tool of claim 1, further comprising clamp meansfor clamping a rail within the tool.
 3. The tool of claim 2, wherein theclamp means includes a clamp aligned with each of the templates.
 4. Thetool of claim 3, further comprising a clamp support connected to theflexible spine and aligned with each of the clamps.
 5. The tool of claim4, further comprising a flexible cover disposed between the clamps andthe flexible spine.
 6. The tool of claim 1, further comprising a clampcarried by the flexible spine; the clamp adapted to hold the curved railagainst the flexible spine.
 7. The tool of claim 6, further comprising aclamp aligned with each of the cutting templates.
 8. The tool of claim7, further comprising a clamp support connected to the flexible spineand aligned with each of the clamps.
 9. The tool of claim 1, furthercomprising a flexible cover disposed between the clamps and the flexiblespine.
 10. The tool of claim 1, wherein each of the templates has angledsidewalls.
 11. The tool of claim 1, wherein each of the templates isadapted to guide a cutting tool to form a picket hole in the curvedrail.
 12. A tool for positioning a plurality of templates with respectto a curved rail having a curvature; the tool comprising: a flexiblespine having a longitudinal direction; the flexible spine adapted toconform to the curvature of the curved rail; the flexible spine having atop surface and a front surface; a plurality of templates connected tothe top surface of the flexible spine and extending over the frontsurface of the spine; each of the templates defining an opening adaptedto guide a cutting tool to form a picket hole in the rail; and aplurality of clamps connected to the spine; each of the clamps adaptedto force the rail toward the front surface of the spine.
 13. The tool ofclaim 12, further comprising a flexible cover disposed between theclamps and the flexible spine; the clamps adapted to force the flexiblecover against the rail.
 14. The tool of claim 13, wherein each of thetemplates has angled sidewalls.
 15. The tool of claim 14, wherein thetemplates are evenly spaced along the spine.
 16. The tool of claim 12,wherein a clamp is aligned with each of the cutting templates.
 17. Thetool of claim 16, further comprising a clamp support connected to theflexible spine and aligned with each of the clamps.
 18. The tool ofclaim 12, wherein each of the template openings has a center; thecenters of the openings being equally space from the front surface ofthe spine.
 19. The tool of claim 12, wherein each of the templates isadapted to guide a cutting tool to form a picket hole in the curvedrail.
 20. A method for forming picket holes in a curved fence rail; themethod comprising the steps of: providing a tool having a flexible spineand a plurality of templates carried by the flexible spine; each of thetemplates having an opening adapted to guide a cutting tool to form apicket hole; connecting the tool to the curved fence rail; and cutting apicket hole in the curved fence rail at the location of each template.